Methods and apparatus to provide a protective barrier to fuel tank coupling apparatus

ABSTRACT

Barrier apparatus for use with fuel tanks are described. An example barrier apparatus includes a protective barrier having a support surface and a wall protruding from the support surface to define a cavity. The support couples the protective barrier to a surface of the fuel tank. A weld pad is disposed within the cavity adjacent the support surface.

CROSS REFERENCE TO RELATED APPLICATION

This patent claims the benefit of U.S. Provisional Patent ApplicationSer. No. 61/386,253, filed on Sep. 24, 2010, entitled METHODS ANDAPPARATUS TO PROVIDE A PROTECTIVE BARRIER TO FUEL TANK COUPLINGAPPARATUS, which is incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to fuel delivery systems and,more particularly, to methods and apparatus to provide a protectivebarrier to fuel tank coupling apparatus.

BACKGROUND

Fuel delivery systems of marine vehicles typically include a fuel tankhaving a plurality of coupling apparatus or components that are coupledto a surface of the fuel tank. For example, the fuel tank couplingapparatus may include, but are not limited to, grade valves, ventvalves, fill line inlet valves, anti-siphon valves, and/or any othercomponent or coupling to be coupled to the fuel tank. These couplingapparatus fluidly couple various components or systems (e.g., a ventingsystem) of the fuel delivery system to the fuel tank.

In some instances, portions of the coupling apparatus (e.g., a barbfitting of a grade valve) may become damaged during shipment of the fueltank (having the coupling apparatus attached to a surface of the fueltank) and/or shipment of the coupling apparatus. Additionally oralternatively, a coupling apparatus is typically composed of athermoplastic material, which provides relatively low resistance totemperatures and, thus, may not be in compliance with certain governmentstandards or regulations (e.g., SCG Fire safety standards per CFR 33).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is schematic representation of an example fuel delivery systemhaving a fuel tank coupling apparatus implemented with an exampleprotective barrier described herein.

FIG. 2A is an enlarged view of the example fuel tank coupling apparatusof FIG. 1.

FIG. 2B illustrates an exploded view of the example fuel tank couplingapparatus of FIGS. 1 and 2A.

FIG. 3 illustrates a plan view the example fuel tank coupling apparatusof FIGS. 1, 2A and 2B.

FIG. 4A illustrates a cross sectional view of the example fuel tankcoupling apparatus taken along line A-A of FIG. 3.

FIG. 4B illustrates an enlarged view of a portion of the example fueltank coupling apparatus of FIG. 4A.

DETAILED DESCRIPTION

In general, an example fuel delivery system described herein may be usedwith marine crafts or vehicles. The example fuel delivery systemdescribed herein includes enhanced or improved fuel tank couplingapparatus or fittings (e.g., a grade valve) that are implemented with anexample protective barrier described herein. An example protectivebarrier apparatus described herein protects the fuel tank couplingapparatus from damage during, for example, shipment (or handling) of thefuel tank and/or during shipment of the coupling apparatus. Additionallyor alternatively, an example protective barrier apparatus describedherein provides compliance with certain government standards (e.g., SCGFire safety standards per CFR 33). More specifically, the exampleprotective barrier apparatus provides local protection to a fuel tankcoupling apparatus such that, in the event of a fire, the protectivebarrier apparatus is destroyed first (e.g., provides a sacrificialwall), thereby providing a duration of time (e.g., greater than two anda half minutes) before the flames reach the fuel tank couplingapparatus.

As used herein, a “fluid” includes, but is not limited to, a liquid suchas fuel (e.g., gasoline), a vapor such as fuel vapor (e.g., gasolinevapor), a gas (e.g., air) and/or any combination or mixture thereof.

FIG. 1 illustrates an example marine fuel delivery system 100 describedherein. The fuel delivery system 100 includes a fuel tank 102 forstoring fuel 104 (e.g., gasoline, diesel fuel, etc.) and has a pluralityof fuel tank coupling apparatus or fittings mounted or coupled to anouter, upper surface 108 of the fuel tank 102. The fuel tank couplingapparatus 110-116 fluidly couple various systems or components of thefuel delivery system 100 to the fuel tank 102. For example, the fueltank coupling apparatus 110-116 may include, but are not limited to,grade valves, vent valves, fill line inlet valves, anti-siphon valves,fuel demand valves, or any other component or coupling apparatus to bemounted or coupled to a surface (e.g., the surface 108, a side surface,etc.) of the fuel tank 102. In this example, a coupling apparatus of thefuel tank 102 include a grade valve assembly 110, a vent valve 112, afuel demand valve 114, and an inlet valve 116. For example, the gradevalve assembly 110 and the vent valve 112 fluidly couple a ventingsystem 118 to the fuel tank 102, the fuel demand valve 114 fluidlycouples a fuel line 120 to the fuel tank 102, and the inlet valve 116fluidly couples a filler tube apparatus 122 to the fuel tank 102.

The venting system 118 equalizes the pressure in the fuel tank 102 toaccommodate volumetric changes (e.g., expansion) in the fuel tank 102.In this example, tubing 124 fluidly couples the vent valve 112 and thegrade valve assembly 110, and the vent valve 112 is fluidly coupled to avent 126 that vents to, for example, the atmosphere. To help reduceventing emissions and/or pollutants to the environment, the ventingsystem 118 may include a vapor collection apparatus 128, which isdisposed between the vent 126 and the vent valve 112 such that an inlet130 of the vapor collection apparatus 128 is fluidly coupled to the ventvalve 112 via tubing 132 and an outlet 134 of the vapor collectionapparatus 128 is fluidly coupled to the vent 126 via tubing 136. Thevapor collection apparatus 128 includes an emission(s)-capturing orfilter material (e.g., an adsorbent material) such as, for example,activated carbon, charcoal, etc., that collects and stores evaporativeemissions such as, for example, hydrocarbons to reduce pollution to theenvironment. The emissions captured and stored by the vapor collectionapparatus 128 are returned or carried to the fuel tank 102 as air isdrawn from the atmosphere to the fuel tank 102 and flows through thevapor collection apparatus 128 between the outlet 134 and the inlet 130via the venting system 118.

FIG. 2A is an enlarged view of the example grade valve assembly 110shown in FIG. 1. FIG. 2B illustrates an exploded view of the examplegrade valve assembly 110 of FIGS. 1 and 2A. Referring to FIGS. 2A and2B, the example grade valve assembly 110 includes valve 202 and aprotective barrier or flange 204. The valve 202 includes a fitting 206(e.g., a barb fitting) that is coupled to a valve body 208 (FIG. 2B).The fitting 206 receives, for example, the tubing 124 of FIG. 1 tofluidly couple the fuel tank 102 to the venting system 118 (FIG. 1). Thefitting 206 and/or the valve body 208 may be composed of a plasticmaterial (e.g., a thermoplastic material), a metallic material (e.g.,stainless steel), etc. The fitting 206 and/or the valve body 208 may bemanufactured via, for example, injection molding as separate pieces andmay be coupled together via snap-fit connection, welding (e.g., plasticwelding), fasteners (e.g., mechanical fasteners, chemical fasteners,etc.) or any other suitable fastening mechanism(s). In some examples,the fitting 206 and the valve body 208 are integrally formed as aunitary piece or structure (e.g., via injection molding).

In this example, the protective barrier 204 substantially surrounds orencircles (e.g., a peripheral or outer edge of) the valve 202 when thevalve 202 is coupled to the protective barrier 204. The protectivebarrier 204 is shown as a cylindrically-shaped body having a cavity 210to define a support surface 212 and an annular wall 214. In otherexamples, the protective barrier 204 may be square, oval or may have anyother shape(s). The support surface 212 may include a recessed surface216 (e.g., an annular recessed surface) to define a stepped or elevatedrim or weld pad 218 adjacent an opening 220 (e.g., a central opening) ofthe support surface 212. In this example, the opening 220 issubstantially axially aligned with an axis 222 of the valve body 208when the valve 202 is coupled to the protective barrier 204. As shown inthis example, the wall 214 protrudes away from the support surface 212about a peripheral edge 224 of the recessed surface 216. The opening 220of the support surface 212 has a diameter that is larger than an outerdiameter of the valve body 208 so that the protective barrier 204slidably receives at least a portion of the valve body 208.

The support surface 212 may also include a plurality of apertures 226for receiving fasteners (e.g., bolts) to couple the grade valve assembly110 to the surface 108 of the fuel tank 102. For example, the fuel tank102 may include fasteners (e.g., nuts) that are molded (e.g., insertmolded) with the surface 108 of the fuel tank 102 to receive thefasteners of the grade valve assembly 110 when coupling the grade valveassembly 110 to the fuel tank 102. Thus, the example grade valveassembly 110 is coupled to the fuel tank 102 via a clamp and compressiongasket.

In this example, at least the weld pad 218 and the protective barrier204 are composed of a thermoplastic material such as, for example, highdensity Polyethelyne, a polyvinyl chloride material, a nylon material, aPolyurethane Prepolymer material and/or any other thermoplasticmaterial(s).

The valve 202 includes a flange 228 disposed between the fitting 206 andthe valve body 208. The flange 228 has an outer diameter that is largerthan the outer diameter of the valve body 208 and the diameter of theopening 220 so that the flange 228 engages the support surface 212 whenthe valve 202 is coupled to the protective barrier 204. In particular,as described in greater detail below, at least a portion of the flange228 engages at least a portion of the weld pad 218. The wall 214includes an access opening or port 230 to enable the tubing 124 to becoupled to the fitting 206 when the valve 202 is coupled to theprotective barrier 204. The access port 230 also includes a bearing orload surface 232 to provide support to, for example, the tubing 124 whenthe tubing 124 is coupled to the fitting 206 to substantially reducestress or loads that may be imparted to the fitting 206 by the tubing124 when the tubing 124 is coupled to the fitting 206.

The grade valve assembly 110 may include a washer 236 (e.g., a metalwasher) that is to be disposed within the cavity 210 and engage therecessed surface 216. The washer 236 includes an opening 238 that iscoaxially aligned with the opening 220 of the support surface 212 andhas a diameter that is larger than an outer diameter of the flange 228of the valve 202 and the diameter of the weld pad 218. The washer 236includes a plurality of apertures 240 that align with the plurality ofapertures 226 of the recessed surface 216 when the washer 236 isdisposed within the cavity 210. Further, in this example, the washer 236includes an opening 242 that is to align with the access port 230 of thewall 214 when the washer 236 is disposed within the cavity 210. In thismanner, the opening 242 provides clearance relative to the fitting 206during assembly of the grade valve assembly 110 and, in some instances,depending on the thickness of the washer 236, the washer 236 will notinterfere with the tubing 124 when the tubing 124 is coupled to thefitting 206. The washer 236 takes or absorbs the load provided by thefasteners when the fasteners couple the grade valve assembly 110 to thesurface 108 of the fuel tank 102.

The grade valve assembly 110 may also include a seal or gasket 244(e.g., a rubber gasket) to provide a seal between the grade valveassembly 110 and the fuel tank 102 when the grade valve assembly 110 iscoupled to the fuel tank 102. As shown in FIG. 2B, the gasket 244includes an opening 246 to receive a portion of the valve body 208 whenthe valve 202 is coupled to the protective barrier 204. The gasket 244also includes a plurality of apertures 248 that align with the pluralityof apertures 226 and 240 of the recessed surface 216 and the washer 236,respectively.

FIG. 3 is a plan view of the example grade valve assembly 110 of FIGS.2A and 2B. FIG. 4A is a cross-sectional view of the example grade valveassembly 110 taken along line A-A of FIG. 3. FIG. 4B is an enlarged viewof a portion of the example grade valve assembly 110 of FIG. 4A.Referring to FIGS. 4A and 4B, the fitting 206 includes an opening 402and the valve body 208 includes an opening 404 that define a passageway406 to allow fuel vapors and/or air to flow through the grade valveassembly 110 between the fuel tank 102 and the atmosphere via theventing system 118 (FIG. 1).

To assemble the valve 202 and the protective barrier 204, the valve 202is disposed within the cavity 210 of the protective barrier 204. Inparticular, the valve body 208 is at least partially disposed within theopening 220 of the protective barrier 204 until at least a portion 408of the flange 228 engages at least a portion 410 of the weld pad 218. Inthis example, the valve 202 is permanently or integrally coupled to theprotective barrier 204. As noted above, both the valve 202 and theprotective barrier 204 are composed of thermoplastic materials such as,for example, High Density Polyethelyne. In some examples, only theportion 408 of the flange 228 and only the portion 410 of the weld pad218 are composed of a thermoplastic material (e.g., HDPE). Because theflange 228 and the weld pad 218 are composed of a thermoplasticmaterial, the valve 202 can be permanently fixed or attached to theprotective barrier 204 via, for example, plastic welding (e.g., hotplate welding). In particular, in this example, the portion 408 of theflange 228 and the portion 410 of the weld pad 218 of the protectivebarrier 204 are heated to a temperature above the melting temperature ofthe materials of the portions 408 and 410 of the flange 228 and the weldpad 218. When the materials of the portions 408 and 410 of the flange228 and the weld pad 218 cool, the materials of the portions 408 and 410integrally mesh and solidify or harden as schematically illustrated withreference numeral 412 of FIG. 4B, thereby permanently attaching thevalve 202 to the protective barrier 204. In other examples, any portionof the valve 202 and/or the protective barrier 204 may be heated topermanently attach or fix the protective barrier 204 and the valve 202.Although not shown, in other examples, the protective barrier 204 may beintegrally formed with the valve body 208 and/or the valve 202 as aunitary piece or structure via, for example, injection molding. Forexample, the protective barrier 204 may be integrally formed with theflange 228.

As shown in FIG. 4A, when the valve 202 is coupled to the protectivebarrier 204, the fitting 206 is positioned adjacent the access port 230of the wall 214 and the valve 202 is at least partially recessed withinthe cavity 210 of the protective barrier 204 so that an upper surface414 of the valve 202 is above an upper edge 416 of the protectivebarrier 204. In some examples, the valve 202 is fully recessed withinthe cavity 210 so that the upper surface 414 of the valve 202 is belowthe upper edge 416 of the wall 214. Thus, the wall 214 may be sized toextend above an upper surface (e.g., the upper surface 414) of a valve(e.g., the valve 202). The washer 236 is then disposed within the cavity210 and adjacent the valve 202 so that the apertures 240 aresubstantially, coaxially aligned with the apertures 226 of the recessedsurface 216 and the opening 238 is coaxially aligned with the axis 222.Further, the opening 242 of the washer 236 is substantially aligned withthe access port 230 of the protective barrier 204 as most clearly shownin FIG. 3. The gasket 244 may be coupled to an under surface 418 of theprotective barrier 204 such that the opening 246 of the gasket 244receives the valve body 208 and the apertures 248 are coaxially alignedwith the apertures 226 of the recessed surface 216 and the apertures 240of the washer 236. The grade valve assembly 110 is then fastened to thesurface of the fuel tank 102 via, for example, fasteners.

As noted above, the grade valve assembly 110 is coupled to the surface108 of the fuel tank 102 via a clamp and gasket compression.Alternatively, in other examples, a surface (e.g., the surface 108 ofFIG. 1) of a fuel tank (e.g., the fuel tank 102 of FIG. 1) may beimplemented with a plurality of insert materials to enable a pluralityof coupling apparatus or components (e.g., the grade valve assembly 110)to be coupled to the surface of the fuel tank via, for example, welding(e.g., plastic welding). Such an example insert material is described inU.S. patent application Ser. No. 12/793,005, which is incorporatedherein by reference in its entirety. In yet other examples, a portion ofthe protective barrier 204 and/or a portion of the valve 202 may becomposed of a first material or a thermoplastic material and the otherportions of the valve 202 and/or the protective barrier may be composedof a second material or a thermoset material. For example, the weld pad218 and/or the flange 228 may be composed of a thermoplastic material(e.g., HDPE) and the wall 214 and the recessed surface 216 of theprotective barrier and/or the valve body 208 and the fitting 206 may becomposed of a thermoset material (e.g., Ethylene Vinyl Alcohol or EVOH).

As noted above, when the grade valve assembly 100 is coupled to the fueltank 102, the protective barrier 204 protects the valve 202 (e.g., thefitting 206) from becoming damaged during shipment (or handling) of thefuel tank 102.

Additionally or alternatively, the protective barrier 204 provides localprotection to the valve 202 in compliance with certain governmentstandards or regulations (e.g., SCG Fire safety standards per CFR 33).For example, many fuel tank coupling apparatus or components arecomposed of thermoplastic materials that have relatively low temperatureresistance and, thus, may not be in compliance with certain governmentstandards because such components composed of low temperaturethermoplastic materials often lack sufficient protection from heatduring a fire. For example, government regulations require a fuel tankcoupling to withstand heat from a fire for a specific duration of time(e.g., for at least two and a half minutes).

The grade valve assembly 110 described herein provides adequateprotection from fire for a duration of, for example, at least two andhalf minutes. For example, if flames propagate around sides of the fueltank 102, the protective barrier 204 blocks the flames from reaching thevalve 202 for a duration of time (e.g., for at least two and a halfminutes). Further, the wall 214 of the protective barrier 204 provides asacrificial structure because the wall 214 substantially surrounds thevalve 202 and, thus, will be destroyed by the flames of a fire beforethe flames reach the valve 202.

Although not shown, in other examples, any one of the plurality ofcoupling apparatus or components of a fuel tank such as, for example, avent valve, a fill line inlet valve, an anti-siphon valve, a fuel demandvalve, or any other fuel tank coupling apparatus or fittings may beimplemented with the example protective barrier 204 described herein.For example, the fuel demand valve 112 and/or the inlet valve 114 of thefuel tank 102 of FIG. 1 may be implemented with the example protectivebarrier 204 described herein.

Although certain apparatus, methods, and articles of manufacture havebeen described herein, the scope of coverage of this patent is notlimited thereto. To the contrary, this patent covers all apparatus,methods, and articles of manufacture fairly falling within the scope ofthe appended claims either literally or under the doctrine ofequivalents.

1. A barrier apparatus for use with a fuel tank comprising: a protectivebarrier having a support surface and a wall protruding from the supportsurface to define a cavity, wherein the support surface is to couple theprotective barrier to a surface of the fuel tank; and a weld paddisposed within the cavity adjacent the support surface.
 2. The couplingapparatus defined in claim 1, wherein the weld pad and the supportsurface are each composed of a thermoplastic material.
 3. The couplingapparatus defined in claim 1, wherein the weld pad and the supportsurface are integrally formed as a unitary structure, and wherein arecessed surface of the support surface defines the weld pad.
 4. Thecoupling apparatus defined in claim 1, wherein the protective barriercomprises a cylindrical body and the wall comprises an annular wall orflange defined by the cylindrical body.
 5. The coupling apparatusdefined in claim 1, wherein the support surface includes a first openingand the weld pad includes a second opening coaxially aligned with thefirst opening.
 6. The coupling apparatus defined in claim 5, furthercomprising a valve, wherein the respective openings of the supportsurface and the weld pad are to receive a body portion of the valveafter the protective barrier is coupled to the surface of the fuel tank.7. The coupling apparatus defined in claim 6, wherein the weld pad is toengage a flange portion of the valve when the valve is disposed in therespective openings.
 8. The coupling apparatus defined in claim 7,wherein the flange has a first diameter that is larger than a seconddiameter of the second opening of the weld pad so that the flangeengages the weld pad when the valve is coupled to the protectivebarrier.
 9. The coupling apparatus defined in claim 8, wherein theflange is coupled to the weld pad of the protective barrier via plasticwelding after the protective barrier is coupled to the surface of thefuel tank.
 10. The coupling apparatus defined in claim 1, furthercomprising a valve, wherein the wall of the protective barriersubstantially encircles a peripheral edge of the valve.
 11. The couplingapparatus as defined in claim 1, further comprising a valve coupled tothe protective barrier, wherein the wall of the protective barrierincludes an access opening to enable tubing to be coupled to a fittingof the valve.
 12. The coupling apparatus as defined in claim 1, whereinthe support surface is composed of a first material and the weld pad iscomposed of a second material different than the first material.
 13. Thecoupling apparatus as defined in claim 1, wherein the support surfacecomprises a plurality of openings to receive a plurality of fasteners tocouple the protective barrier to the fuel tank.
 14. The couplingapparatus as defined in claim 1, further comprising a washer disposedwithin the cavity of the protective barrier, the washer disposed on thesupport surface and adjacent the weld pad.
 15. A method of attaching acoupling apparatus to a fuel tank, the method comprising: coupling abarrier to an outer surface of the fuel tank, the barrier comprising asupport surface and a wall that define a cavity; providing a weld padwithin the cavity such that a first side of the weld pad engages thesupport surface; disposing a valve within the cavity of the barrierafter the barrier is coupled to the outer surface such that a flangeportion of the valve engages the weld pad; and heating the weld pad andthe flange portion of the valve body to a temperature greater than amelting temperature of a material of the flange portion and the weldpad.
 16. A method of claim 15, wherein coupling the barrier to the fueltank comprises fastening the barrier to the surface of the fuel tank viafasteners that pass through respective openings of the support surface.17. A method of claim 16, further comprising coupling the barrier to thesurface of the fuel tank prior to coupling the valve and the barrier.18. A method of claim 15, further comprising cooling the weld pad andthe flange portion so that the weld pad and the flange portionintegrally mesh or solidify to attach the valve to the barrier.
 19. Acoupling apparatus for use with a fuel tank, comprising means forprotecting a valve, the means for protecting substantially surrounding aperipheral edge of a valve; and means for attaching the valve to themeans for protecting, the means for attaching integrally formed with themeans for protecting, and the means for protecting coupled to the fueltank prior to the means for attaching the valve to the means forprotecting.
 20. The coupling apparatus of claim 19, wherein the meansfor protecting and the means for attaching further comprise means forreceiving a body portion of the valve such that a flange portion of thevalve engages the means for attaching the valve when the valve isdisposed within the means for receiving.